ENGINE - POSITION ON STAND AND REMOVE

Operation 1004D40 · REMOVE ENGINE AND WASH

1.4 16v

1. Undo bolts (1a) and remove engine flywheel (1b) complete with safety washer (1c).

2. Undo the bolt and remove the flywheel lock.

3. Undo bolt (3a) and remove guards (3b).

1. Using the tool and a hydraulic lift, place the engine on the overhaul stand.

- Support the engine using the mounting tools and a hydraulic lift.

- Undo the bolts securing the engine block to the overhaul stand mount.

- Place the engine on a suitable board.

- Place the engine flywheel guards in position and tighten the lower guard bolt.

- Place the flywheel in position complete with safety washer, taking care over the centring bush. Screw in the new bolts without tightening to torque.

- Fit the flywheel lock.

- Tighten the new bolts securing the engine flywheel to the recommended torque.

1.2 8v

1. Fit flywheel lock (1a), unscrew bolts (1b) and remove engine flywheel (1c)

- Remove the flywheel lock.

- Remove the centring bush guard.

- Fit the mount on the crankcase.

- Using the tool and a hydraulic lift, place the engine on the overhaul stand.

- Support the engine using the mounting tools and a hydraulic lift.

- Undo the bolts securing the engine block to the overhaul stand support.

- Position the flywheel guard and fit the engine flywheel.

- Fit the flywheel lock.

- Tighten the new bolts securing the engine flywheel to the recommended torque.

1.3 Multijet

1. Keep the flywheel lock fitted, refer to

Op. 1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, DISMANTLE AND REASSEMBLE

1. Loosen the bolts fixing the crankshaft pulley.

2. With the engine timed, refer to

Op. 1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, DISMANTLE AND REASSEMBLE

loosen the left hand thread bolt securing the pulley mounting flange to the crankshaft.

1. Undo the bolts (1a) and remove the engine flywheel (1b).

2. Remove the flange.

The bolts securing the flywheel are pre-treated with sealant, therefore they should be replaced each time they are removed.

3. Remove the flywheel lock.

1. Fit the universal tool on the engine block.

- Secure and support the engine using a hydraulic lift fitted with chains.

- Position the engine on the overhaul stand using the universal tool fitted previously.

- Release the engine from the hydraulic lift hoist.

- Secure and support the engine using a hydraulic lift fitted with chains.

- Undo the fastenings securing the universal tool to the overhaul stand, then position the enigne on a special workbench using the hydraulic lift.

- Undo the fastenings and remove the universal tool from the engine.

1. Fit the flywheel lock.

2. Place the engine flywheel (2a), complete with flange (2b), back in its housing and secure it tightening the new bolts (2c) to the recommended torque.

1. With the timing template fitted on the exhaust side camshaft, refer to

Op. 1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, DISMANTLE AND REASSEMBLE

proceed with tightening the left hand thread bolt securing the pulley mounting flange to the crankshaft.

2. Tighten the bolts fixing the crankshaft pulley to the recommended torque.